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Cost-Effective Maintenance


Cost-Effective Maintenance


  • Interactive course with open discussions, team exercises, videos, case studies, and presentations.
  • Participants have the opportunity to discuss their organization’s maintenance approach and develop maintenance plans with the trainer and other participants.

Course Objectives:

  • Understand the definition and principles of cost-effective maintenance.
  • Calculate the total maintenance cost for their production facility.
  • Build a work case study to eliminate waste and develop low-cost maintenance without compromising reliability.
  • Use the excellence model to improve fixed maintenance costs.
  • Explain the foundations of cost-effective safety and legal compliance.
  • Focus on reliability efforts in a cost-effective manner.
  • Develop a methodology to reduce costs, integrate reliability, and improve safety.

Target Audience:

  • Maintenance managers, supervisors, planners, schedulers, reliability engineers, project managers and engineers, operations managers, transformation managers, operations supervisors, and individuals being trained for these positions.
  • Contractors involved in maintenance and shutdown activities for clients.

Program Content:

  1. Understanding the total cost of maintenance.
  • Definition of total maintenance cost.
  • Measurement criteria.
  • Best practices resources.
  • Key elements of fixed costs.
  • Cost of lost production.
  • Cost of non-compliance.
  • Adding value through maintenance.
  • Developing a balanced approach to cost-effective maintenance.
  • Factors influencing maintenance cost effectiveness.
  • Changing spending behaviors.
  1. Modern maintenance strategy.
  • Evolution of maintenance.
  • Understanding where money can be invested and wasted.
  • Importance of planning.
  • Relationship between fixed costs and maintenance performance.
  • Shifting mindset.
  • Moving beyond cost, reliability, or safety reduction.
  • Towards cost, reliability, and safety reduction.
  • Modern maintenance strategy and asset management.
  • Adding value through innovative maintenance and alignment with operational teams.
  1. Fundamentals of reducing fixed costs.
  • Understanding major spending categories.
  • Determining maintenance costs.
  • Root cause identification of expenses.
  • Management risks associated with averages.
  • Developing a program to reduce maintenance costs.
  • Establishing key performance indicators and sustainable change.
  1. Areas of focus for reducing fixed costs.
  • Waste reduction.
  • Understanding different types of maintenance.
  • Common causes of waste.
  • Importance of planning.
  • Risk-based maintenance principles.
  • Importance of maintenance standards.
  • Efficiency improvements through smart workflows.
  • Identifying efficiency opportunities.
  • Improving downtime management.
  • Enhancing maintenance methods.
  • Learning from other industries.
  • Implementing a planned maintenance system.
  • Supply chain cost reduction.
  • Contractor strategies.
  • Spare parts and materials.
  • Equipment services and auctions.
  1. Plant performance and reliability improvement.
  • Excellence model for reliability improvement.
  • Reliability roadmap.
  • Ensuring effective and efficient reliability improvement.
  • Understanding different types of maintenance.
  • Overall equipment effectiveness and other performance measures.
  • Improving asset life.
  • Learning from experience.
  • Role of operations.
  • Utilizing different maintenance types for performance improvement.
  • Achieving the same performance at lower costs.
  1. Cost-effective health, safety, and environment (HSE).
  • Value of improving health, safety, and environment.
  • How poor performance incurs unnecessary costs when safety is achieved.
  • Integrating health, safety, and environment into a broader maintenance strategy.
  • Legislation management.
  • Risk-based inspection principle.
  • Cost reduction for compliance.
  1. Importance of shutdown management.
  • Assets of the excellence model and why it was developed.
  • Graphic model – critical elements for success.
  • Planned model – exploring sub-elements.
  • Detailed model – a blueprint for success.
  • Importance of strategy and front-end loading principle.
  • Leaders transitioning to organized work processes.
  • Safety operations and quality control.
  • Defining proper shutdown.
  • Planning and logistics services.
  • Execution and review.
  1. Economic science of shutdown from prediction to closure.

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